Crancase cover cracked-Maybe Woodruff problem???

[rekless]

I have to say, I'm trying sooo hard to remain a blue fan, but geez. Last night, I pulled my crankcase cover off to check the staor bolts that everybody was talking about a few days ago. Upon getting the crankcase cover off, I immediately notice that the part of the crankcase cover which holds the idler gear in place, was broken. It appears to me that the bike probably needed to shear the woodruff, but after the service bulletin had been done, it couldn't shear the key. The pressure in turn, pushed really hard on the idler gear and broke the crancase cover. BikeBandit has this part for $86.00, but I'm thinking of pulling the two idler gears out and pulling all of the starter stuff off and making it a kicker only. Does anybody have any input???? Does anybody make a good aftermarket cover??? Finally...will it hurt anything for me to pull both idler gears and run it, providing the hole where the starter is, is covered. Please chime in...especially you guys that have alot of Woodruff experience. TIA rekless ?

BTW: If anyone wants pics of the damage, let me know and I will email them. I dont know how to post them on TT. I took some really good pics of the damage. Off to the local Yamaha shop to see if they will take care of the problem or help me out at least.

[Poway Rider]

I had the same problem with a cracked cover. I just upgraded to the '04 starter to eliminate the issue for good. I can't afford to be 20 miles into the desert and have a woodruff failure. I love the bike otherwise.

[rekless]

Just got back from the dealer and it's $120.00 for a new cover. I also searched high and low, and it appears that no one makes a aftermarket aluminum cover for this application. Someone please correct me. Looks like I'm going to go the kick only route for a while. Is there any reason that I can't pull the battery out also, along with the starter and save several pounds?? Will the lights still work without the battery? rekless ?

[Indy_WR450]

You guys must be fairly new to this forum. The 04 starter upgrade solves all these issues. E-Start is the way to go. Check out the web site www.wr450.com and check out the instructions in the photo section and you can eliminate the replacement side cover with the bushing that can press in to the 03 cover. ?

[lipskid]

Starter, battery, idler gears, and positive battery cable, added up to ~6.5 lbs. on my bathroom scale. ?

IMO

Pro's- no more woodruff worries. Minor(very) weight savings. You can cut the battery tray out of the airbox cover(very noticable improvement). It's CHEAP. 4 bucks at NAPA for a 1 1/8" core hole plug(expandable). Oh yeah, and a couple bolts(shorter) to fill the starter mount holes to keep them clean... ... And new jets. The most expensive part of the whole thing.

Cons- No more happy button.? You have to remember how to put the thing back together before you sell it. It will cost you about 20 bucks for a new air box lid. It's hot, you're tired, you eat sh*t, and your buddy who still has his Button, gets to watch you suffer. ?

[ddialogue]

...and your buddy who still has his Button, gets to watch you suffer...

What you meant to say was "your buddy...gets the enjoyment of watching you suffer..."

?

[The_Blue_One]

Same thing happened to me. I pulled all the e-start stuff off and ran it that way for almost a year.No troubles and i didn't miss the button at all.

Here is what i did.

I had the starter hole welded up for $20. I then pulled the starter,idler gear and all the related wiring. I pulled the battery tray out of the airbox(without cutting it) and reused it's spacers(they're lightly pressed in) It saves about 8 lbs according to my scale and was fairly noticeable.

The ground wire that goes down to the starter needs to stay.I moved it to one of the air box bolts and it worked fine.

I recently put it all back on to sell my bike(new cover from ddialogue ) and it took about an hour.The battery still had enough charge to start up the bike. ?

I can post up some pics of the cover if you want.

[rekless]

Blue One,

I think I already screwed the proverbial pooch. I cut the ground wire and the hot wire that lead to the starter. What wont work with the wires cut? I only cut maybe 5" off of both, just to keep them from dangling. I then taped them off, to seal them up. Maybe I can re-route the ground wire and hook it to something...if it has to be grounded??? Thanks, rekless ?

[rekless]

Two more questions....I had the hole welded up where the starter used to reside and put the bike back together. I had to pull the cam chain tensioner out to get the starter out. When I pulled the tensioner out, I could see the motor slowly turn as I pulled the thing out. After getting the starter out, I put the tensioner back in per my owners manual. Didn't turn the motor over at all while the tensioner was out. Did I hurt anything by removing the tensioner for 2 minutes. I started the bike when I was finished and everything seemed okay UNTIL..................

I shut the bike off and I could hear this whirring for about 1-2 seconds, after the motor stopped. I'm thinking that this is probably just the "one-way" clutch deal that my idler gears used to be hooked to. Any thoughts would be welcome. The wasn't loud, just noticeable.TIA, rekless ?

[The_Blue_One]

Blue One,

I think I already screwed the proverbial pooch. I cut the ground wire and the hot wire that lead to the starter. What wont work with the wires cut? I only cut maybe 5" off of both, just to keep them from dangling. I then taped them off, to seal them up. Maybe I can re-route the ground wire and hook it to something...if it has to be grounded??? Thanks, rekless??

I could of swore my bike wouldn't run without the wire going to the back bolt grounded. If your bike doesn't start just tie the ground wire down to the frame.If it does then i'm wrong

[rekless]

Blue One, Last night when I started my bike, the ground wire was arcing off the frame and I thought..."What the heck is that dern clicking noise??? Anyways, I did exactly what you said...I pulled the big ground wire out and connected that small lead that goes to the battery, to the frame. Thanks, rekless ?

[RoosterJ]

It might not hurt to pull the starter clutch gear out as well, kinda like pulling a rooten tooth, be sure and check the stator bolts for tightness and use threadlocker. sounds like this blue bike is on the way to be reliable. who needs the e button any way. ?

[rekless]

I will say that thanks to JD kit installed last year, and some fine tuning, my bike kicks as easy as any I've ever seen. Usually first kick....hot or cold. Thanks guys for all your help. rekless ?